Forming a wellbore casing while simultaneously drilling a wellbore

Abstract

A wellbore casing is formed simultaneously with the drilling out of the wellbore.

what is claimed is:  
     
       1. A method of forming a wellhead, comprising: 
       drilling a wellbore;  
       positioning an outer casing at least partially within an upper portion of the wellbore;  
       positioning a first tubular member within the outer casing;  
       expanding at least a portion of the first tubular member into contact with an interior surface of the outer casing;  
       positioning a second tubular member within the outer casing and the first tubular member; and  
       expanding at least a portion of the second tubular member into contact with an interior portion of the outer casing;  
       wherein, after expanding the portions of the first and second tubular members into contact with the interior portion of the outer casing, at least a portion of the second tubular member is positioned within the first tubular member; and  
       wherein, after expanding the portions of the first and second tubular members into contact with the interior portion of the outer casing, the first tubular member and the second tubular member define an annular passage there between.  
     
     
       2. The method of  claim 1 , further including pressurizing at least a portion of the interiors of the first and second tubular members. 
     
     
       3. The method of  claim 2 , wherein the pressurizing of the portion of the interior region of the first and second tubular members is provided at reduced operating pressures during a latter portion of the expansions. 
     
     
       4. The method of  claim 1 , further comprising: 
       sealing the contact between the first and second tubular members and the outer casing.  
     
     
       5. The method of  claim 1 , further comprising: 
       supporting the expanded first and second tubular members using their contacts with the outer casing.  
     
     
       6. The method of  claim 1 , further including extruding the first and second tubular members off of a mandrel. 
     
     
       7. The method of  claim 6 , further comprising: 
       injecting fluidic material beyond the mandrel.  
     
     
       8. The method of  claim 6 , wherein a region of the first and second tubular members beyond the mandrel is pressurized. 
     
     
       9. The method of  claim 1 , further comprising: 
       fluidicly isolating an interior region of the first tubular member from an exterior region of the first tubular member.  
     
     
       10. The method of  claim 1 , further comprising: 
       fluidicly isolating an interior region of the second tubular member from an exterior region of the second tubular member.  
     
     
       11. The method of  claim 1 , wherein, after expanding the portions of the first and second tubular members into contact with the interior portion of the outer casing, the first tubular member, the second tubular member, and the outer casing are positioned substantially concentrically with respect to one another. 
     
     
       12. A wellbore casing, comprising: 
       a first tubular member; and  
       a second tubular member coupled to the first tubular member in an overlapping relationship by a process comprising:  
       positioning the second tubular member within the first tubular member with at least a portion of the second tubular member overlapping with a portion of the first tubular member; and  
       radially expanding the overlapping portions of the first and second tubular members;  
       wherein the inner diameter of the radially unexpanded portion of the first tubular member is substantially equal to the inner diameter of the radially expanded portion of the second tubular member.  
     
     
       13. The wellbore casing of  claim 12 , wherein the first tubular member includes a first thin wall section, wherein the second tubular member includes a second thin wall section, and wherein the process for coupling the first and second tubular members in an overlapping relationship further comprises: 
       overlapping the first thin wall section of the first tubular member with the second thin wall section of the second tubular member; and  
       radially expanding the first and second thin wall sections of the first and second tubular members.  
     
     
       14. The wellbore casing of  claim 13 , wherein the first tubular member includes a first compressible member coupled to the first thin wall section, and wherein the second tubular member includes a second compressible member coupled to the second thin wall section. 
     
     
       15. The wellbore casing of  claim 14 , wherein the process for coupling the first and second tubular members in an overlapping relationship further comprises: 
       radially expanding the first thin wall section and the first compressible member and the second thin wall section and the second compressible member.  
     
     
       16. The wellbore casing of  claim 12 , wherein the inner diameter of the radially unexpanded portion of the first tubular member is substantially constant. 
     
     
       17. The wellbore casing of  claim 12 , wherein the inner diameter of the radially expanded portion of the second tubular member is substantially constant. 
     
     
       18. The wellbore casing of  claim 12 , wherein the inner diameter of the radially unexpanded portion of the first tubular member is substantially constant; and wherein the inner diameter of the radially expanded portion of the second tubular member is substantially constant. 
     
     
       19. A wellbore casing, comprising: 
       a first tubular member having a first inside diameter; and  
       a second tubular member having a second inside diameter substantially equal to the first inside diameter coupled to the first tubular member in an overlapping relationship;  
       wherein the first and second tubular members are coupled by a process comprising deforming the overlapping portions of the first and second tubular members; and  
       wherein the second tubular member is radially expanded by the process comprising:  
       supporting the second tubular member and a mandrel within the wellbore using a support member;  
       injecting a fluidic material into the wellbore;  
       pressurizing an interior region of the mandrel; and  
       displacing a portion of the mandrel relative to the support member.  
     
     
       20. The wellbore casing of  claim 19 , wherein the second tubular member is deformed by the process of: 
       placing the first and second tubular members in an overlapping relationship;  
       radially expanding at least a portion of the first tubular member; and  
       radially expanding the second tubular member.  
     
     
       21. The wellbore casing of  claim 19 , wherein the injecting includes: 
       injecting hardenable fluidic sealing material into an annular region located between the borehole and the exterior of the second liner; and  
       injecting non hardenable fluidic material into an interior region of the mandrel.  
     
     
       22. The wellbore casing of  claim 21 , further comprising: 
       fluidicly isolating the annular region from the interior region of the mandrel before injecting the non hardenable fluidic material into the interior region of the mandrel.  
     
     
       23. The wellbore casing of  claim 21 , wherein the injecting of the non hardenable fluidic material is provided at reduced operating pressures and flow rates during an end portion of the radial expansion. 
     
     
       24. The wellbore casing of  claim 19 , wherein the fluidic material is injected into one or more annular pressure chambers defined within the mandrel. 
     
     
       25. The wellbore casing of  claim 19 , further comprising: 
       fluidicly isolating an interior region of the mandrel from an exterior region of the mandrel.  
     
     
       26. The wellbore casing of  claim 19 , further comprising: 
       sealing the overlap between the first and second tubular members.  
     
     
       27. The wellbore casing of  claim 19 , further comprising: 
       supporting the second tubular member using the overlap with the first tubular member.  
     
     
       28. The wellbore casing of  claim 19 , wherein the mandrel reciprocates relative to the support member. 
     
     
       29. The wellbore casing of  claim 19 , wherein the mandrel is displaced in a first direction during the pressurization of the interior region of the mandrel; and wherein the mandrel is displaced in a second direction during a de-pressurization of the interior region of the mandrel. 
     
     
       30. The wellbore casing of  claim 19 , wherein the second tubular liner is maintained in a substantially stationary position by the support member during the pressurization of the interior region of the mandrel. 
     
     
       31. The wellbore casing of  claim 30 , wherein the second tubular liner is supported by the mandrel during a de-pressurization of the interior region of the mandrel. 
     
     
       32. The wellbore casing of  claim 19 , wherein the first inside diameter of the first tubular member is substantially constant. 
     
     
       33. The wellbore casing of  claim 19 , wherein the second inside diameter of the second tubular member is substantially constant. 
     
     
       34. The wellbore casing of  claim 19 , wherein the first inside diameter of the first tubular member is substantially constant; and wherein the second inside diameter of the second tubular member is substantially constant.